{"id":23431,"date":"2021-11-18T12:17:38","date_gmt":"2021-11-18T11:17:38","guid":{"rendered":"https://www.istec.com/de/?p=23431"},"modified":"2026-07-27T09:24:40","modified_gmt":"2026-07-27T07:24:40","slug":"4-first-checks-when-installing-commissioning-and-troubleshooting-an-overspeed-protection-system","status":"publish","type":"post","link":"https://www.istec.com/de/4-first-checks-when-installing-commissioning-and-troubleshooting-an-overspeed-protection-system/","title":{"rendered":"4 first checks when installing, commissioning and troubleshooting an overspeed protection system"},"content":{"rendered":"

It is essential to verify the functioning of every individual component of an overspeed protection system. This can be done during its installation, commissioning / turnarounds or troubleshooting. As this is a critical process and downtime is costly, it is crucial to have a solid step-by-step plan. This checklist provides an overview of the steps that should be taken to verify the safety and reliability of the sensors, installation, system and signal.

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Note: this checklist is part of our Speed bookazine, which you can request for free via this page » 

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Sensor verification

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The following checks can be done when the machine has stopped and the sensors are accessible:

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1.1 What is the type of sensor being used?

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1.2 What is the measuring range of the sensor?

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    • Action: refer to the sensor’s datasheet for this information.
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    • Action: compare this information with the settings of the overspeed detection system.
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2.1 What is the maximum allowable distance of the used sensor and the pole wheel?

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2.2 How is the signal output affected by this distance?

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    • Action: refer to the sensor’s datasheet for this information.
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    • Action: measure the gap between the sensor and the pole wheel.\n
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        • Tools: feeler gauges or another type of depth measuring tool.
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3.1 Does the sensor need to be aligned in a certain direction in relation to the pole wheel?

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3.2 What is the maximum side and angular misalignment that is allowed for this sensor?

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    • Action: refer to the sensor’s datasheet for this information.
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    • Action: verify the alignment between the sensor and the pole wheel.
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4.1 How is the sensor mounted on the machine i.e., through the bearing casing or on a bracket?

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4.2 How rigid is this setup?

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4.3 Is the setup properly secured to a fixed point of the machine?

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    • Action: verify the installation of the speed sensors and the stiffness of the bracket.
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    • Action: verify the tightness of all bolts and nuts of the brackets and sensors.\n
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        • Tools: spanners
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5.1 What is the shape of the pole wheel?

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5.2 What is the module of the pole wheel?

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5.3 What is the height of the teeth on the pole wheel?

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    • Action: verify the dimensions of the pole wheel on the actual machine, or through its drawings.
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    • Action: compare the pole wheel dimensions to the specifications of the sensor and the overspeed system.
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Installation verification

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The following checks can be done when the machine is running. However, if there is an increased risk, the machine should be stopped before doing these checks.

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1.1 What type of cables are being used to transfer the signals from the machine to the overspeed detection system?

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1.2 How is the grounding and shielding of all the sensor cables? Is it connected as described in the user manual of the overspeed detection system?

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1.3 Is there a clear grounding philosophy with single ended shielding, to prevent ground loops?

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1.4 Verify the clear differences in the installation between PE, IE and IS.

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    • Action: check the type of cable from the machine, in every junction box, to the overspeed system.
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    • Action: when the cable not shielded per overspeed measurement, consider replacing this cable.
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    • Action: measure the resistance, current, and voltage between the shielding and the associated earth connections.\n
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        • Tools: multimeter
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2.1 How are the wires terminated in the junction boxes?

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2.2 Are the terminals properly fastened?

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2.3 Are the wire-end ferrules used correctly?

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    • Action: check every junction box for proper connections.\n
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        • Tools: screwdriver
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System verification

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1.1 How is the device configured?

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1.2 Do all of the in- and outputs work as its intended?

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1.3 What type of voting structure is used?

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    • Action: go through the overspeed detection system configuration and look for anomalies and deviations from its standard functionality.
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    • Action: inject a speed signal (simulation) into the overspeed system, with the same characteristics as the actual signal.
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    • Action: check if the analog and digital outputs change when certain values are met.
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    • Action: verify the functionality of the voting structure by going through all of the logical combinations.\n
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        • Tools: configuration program of the overspeed detection system, speed simulating equipment, and a multimeter
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2.1 How is the overspeed system wired on the terminals?

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2.2 Does the system have internal wiring?

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    • Action: verify all of the wiring on and in the system for proper connections.\n
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      • Tools: screwdriver
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Signal verification

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The following checks to verify the signal can be done when the machine is running:

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1.1 What shape does the signal have right before it enters the overspeed detection system?

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1.2 Is there noise present on the incoming signal?

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1.3 How stable is the sensor power supply?

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    • Action: measure the shape, noise, and AC and DC levels of the incoming speed signals during a run-up and during nominal speed.
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    • Action: store this data for future reference.
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    • Action: when replacing an overspeed detection system, measure the incoming signals on the old system first before replacing the system.\n
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        • Tools: oscilloscope
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2.1 How do the measured signal levels compare to the trigger level of the overspeed detection system?

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    • Action: measure the AC and DC levels of the incoming signal and verify this with the configuration.\n
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        • Tools: oscilloscope and the configuration program of the overspeed detection system.
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3.1 How stable and even is one revolution of the pole wheel?

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3.2 Verify the eccentricity of the pole wheel during different speeds.

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3.3 Does the pole wheel have enclosed magnetic fields?

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    • Action: measure the eccentricity close to the pole wheel.
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    • Action: measure the magnetic stability of the pole wheel with eddy current shaft vibration sensor on the pole wheel.
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    • Action: measure the magnetic fields in the pole wheel when the machine is stopped and the pole wheel is accessible.\n
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        • Tools: eddy current shaft vibration sensors (if already present) and a Gauss meter.
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\n","protected":false},"excerpt":{"rendered":"

It is essential to verify the functioning of every individual component of an overspeed protection system. This can be done during its installation, commissioning / turnarounds or troubleshooting. As this is a critical process and downtime is costly, it is crucial to have a solid step-by-step plan. This checklist provides an overview of the steps …

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